Method and apparatus for maintaining a constant load current with line voltage in a switch mode power supply

ABSTRACT

A power supply regulator including a variable current limit threshold that increases during an on time of a switch. In one aspect, a power supply regulator includes a comparator coupled to receive a signal representative of a current through a switch during an on time of the switch. The comparator is further coupled to receive a variable current limit threshold that increases during the on time of the switch. The power supply regulator also includes a feedback circuit coupled to receive a feedback signal representative of an output of a power supply. A control circuit is also included and is coupled to the switch, to an output of the comparator, and to an output of the feedback circuit. The control circuit is coupled to control a switching of the switch in response the output of the comparator and the output of the feedback circuit to regulate the output of the power supply.

RELATED APPLICATION

This application is a continuation of U.S. Application Ser. No.12/581,054, filed Oct. 16, 2009, now pending, which is a continuation ofU.S. application Ser. No. 11/784,560, filed Apr. 6, 2007, now U.S. Pat.No. 7,646,184, which is a continuation of U.S. application Ser. No.11/397,524, filed Apr. 3, 2006, now U.S. Pat. No. 7,215,105 B2, which isa continuation of U.S. application Ser. No. 10/892,300, filed Jul. 15,2004, now U.S. Pat. No. 7,110,270 B2, which is a continuation of U.S.application Ser. No. 10/253,307, filed Sep. 23, 2002, now U.S. Pat. No.6,781,357 B2, which claims the benefit of and priority to U.S.Provisional Application Ser. No. 60/325,642, filed Sep. 27, 2001,entitled “Method And Apparatus For Maintaining A Constant Load CurrentWith Line Voltage In A Switch Mode Power Supply,” now expired. U.S.Provisional Application Ser. No. 60/325,642, U.S. Non-Provisionalapplication Ser. No. 12/581,054 and U.S. Pat. Nos. 6,781,357, 7,110,270,7,215,105 and 7,646,184 are hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to power supplies and, morespecifically, the present invention relates to a switched mode powersupply.

2. Background Information

All electronic devices use power to operate. A form of power supply thatis highly efficient and at the same time provides acceptable outputregulation to supply power to electronic devices or other loads is theswitched-mode power supply. In many electronic device applications,especially the low power off-line adapter/charger market, during thenormal operating load range of the power supply an approximatelyconstant output voltage is required below an output current threshold.The current output is generally regulated below an output voltage inthis region of approximately constant output voltage, hereafter referredto as the output voltage threshold.

In known switched mode power supplies without secondary current sensingcircuitry, minimizing the variation of the output current at the outputvoltage threshold is performed with complex control schemes. Typically,these schemes include the measurement of input voltage, output diodeconduction time and peak primary current limit. Some or all of thismeasured information is then used to control the regulator in order toreduce the variation of the output current at the output voltagethreshold.

SUMMARY OF THE INVENTION

A power supply that maintains an approximately constant load currentwith line voltage below the output voltage threshold is disclosed. Inone embodiment, a regulation circuit includes a semiconductor switch andcurrent sense circuitry to sense the current in the semiconductorswitch. The current sense circuitry has a current limit threshold. Theregulation circuit current limit threshold is varied from a first levelto a second level during the time when the semiconductor switch is on.In one embodiment, the regulation circuit is used in a power supplyhaving an output characteristic having an approximately constant outputvoltage below an output current threshold and an approximately constantoutput current below an output voltage threshold. In another embodiment,a power supply is described, which includes a power supply input and apower supply output and that maintains an approximately constant loadcurrent with line voltage below the output voltage threshold. In oneembodiment, the power supply has an output characteristic having anapproximately constant output voltage below an output current thresholdand an approximately constant output current below an output voltagethreshold. A regulation circuit is coupled between the power supplyinput and the power supply output. The regulation circuit includes asemiconductor switch and current sense circuitry to sense the current inthe semiconductor switch. The current sense circuitry has a currentlimit threshold. The regulation circuit current limit threshold isvaried from a first level to a second level during the time when thesemiconductor switch is on. In another aspect, the current limitthreshold being reached coincides with the power supply outputcharacteristic transitioning from providing an approximately constantoutput voltage to supplying an approximately constant output current. Inyet another aspect, the semiconductor switch is a MOSFET. Additionalfeatures and benefits of the present invention will become apparent fromthe detailed description and figures set forth below.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention detailed illustrated by way of example and notlimitation in the accompanying figures.

FIG. 1 is a schematic of one embodiment of a switched mode power supplyregulator in accordance with the teachings of the present invention.

FIG. 2 is a diagram illustrating one embodiment of sawtooth, duty cycleand intrinsic current limit waveforms in accordance with the teachingsof the present invention.

FIG. 3 shows one embodiment of a power supply that has an approximatelyconstant voltage and constant current characteristic in accordance withthe teachings of the present invention.

FIG. 4 shows one embodiment of a power supply that has an approximatelyconstant voltage and constant current characteristic in accordance withthe teachings of the present invention.

FIG. 5 is a diagram illustrating the typical relationship between theoutput current and output voltage of one embodiment of a power supply inaccordance with the teachings of the present invention.

DETAILED DESCRIPTION

Embodiments of methods and apparatuses for maintaining a power supplyoutput current substantially constant independent of input voltage atthe point where the power supply output characteristic transitions fromproviding an approximately constant output voltage to supplying anapproximately constant output current are disclosed. In the followingdescription, numerous specific details are set forth in order to providea thorough understanding of the present invention. It will be apparent,however, to one having ordinary skill in the art that the specificdetail need not be employed to practice the present invention. In otherinstances, well-known materials or methods have not been described indetail in order to avoid obscuring the present invention.

Reference throughout this specification to “one embodiment” or “anembodiment” means that a particular feature, structure or characteristicdescribed in connection with the embodiment is included in at least oneembodiment of the present invention. Thus, the appearances of thephrases “in one embodiment” or “in an embodiment” in various placesthroughout this specification are not necessarily all referring to thesame embodiment. Furthermore, the particular features, structures orcharacteristics may be combined in any suitable manner in one or moreembodiments.

In one embodiment here, a switched mode power supply is described inwhich the output current below the output voltage threshold, isregulated to be approximately constant. This provides an approximateconstant voltage/constant current output characteristic. The outputcurrent level at the output voltage threshold in known power suppliessensed at the output of the power supply to provide feedback to aregulator circuit coupled to the primary winding of the power supply. Ifhowever, the approximate constant current functionality is achievedwithout feedback from the secondary winding side of the power supply,the output current at the output voltage threshold is a function of apeak current limit of the primary regulator.

Embodiments of the present invention reduce the variation of the outputcurrent at the output voltage threshold by reducing the peak currentlimit variation with changing input voltage. In general, the intrinsicpeak current limit is set by internal circuitry in the regulator to beconstant. In one embodiment, once the drain current reaches a currentlimit threshold, the switching cycle should, in theory, terminateimmediately. However, a fixed delay is inherent from the time thethreshold is reached until the power metal oxide semiconductor fieldeffect transistor (MOSFET) is finally disabled. During this delay, thedrain current continues to ramp up at a rate equal to the direct current(DC) input voltage divided by the primary inductance of the transformer(drain current ramp rate). Therefore, the actual current limit is thesum of the intrinsic current limit threshold and a ramp-rate dependentcomponent (the overshoot), which is the drain current ramp ratemultiplied by the fixed delay. Thus, at higher DC input voltages, theactual current limit ramps to a higher level above the intrinsic currentlimit level than at low DC input voltages. This can result in variationsin the output current delivered to the load at the output voltagethreshold over a range of input line voltages.

The actual current limit is the sum of the intrinsic current limit andthe ramp-rate dependent component (the overshoot). The goal is tomaintain a constant actual current limit over DC input voltagevariations. Since the ramp-rate component (the overshoot) increases withrespect to the DC input voltage, the only way to maintain a relativelyconstant current limit would be to reduce the intrinsic current limitthreshold when the DC input voltage rises.

In discontinuous power supply designs, the point in time during theswitching cycle in which the current limit is reached is dependent onthe DC input voltage. In fact, the time it takes from the beginning ofthe cycle to the point where current limit is inversely proportional tothe DC input voltage. Thus, the time elapsed from the beginning of thecycle can be used to gauge the DC input voltage.

Therefore, in order to create an intrinsic current limit which decreasesrelative to the DC input voltage, the time elapsed can be used. It issimply necessary to increase the intrinsic current limit as a functionof the time elapsed during the cycle. A first approximation forincreasing the intrinsic current limit with time can be obtained byusing the Equation 1 below:I _(LIM-INTRINSIC) =K ₁ +K ₂ *t _(elapsed),  (Equation 1)where is I_(LIM-INTRINSIC) the intrinsic current limit, K₁ and K₂ areconstants and t_(elapsed) is the time elapsed.

In one embodiment, the time elapsed can be detected by the internaloscillator output waveform. In one embodiment, this waveform is atriangular one. It starts at its minimum at the beginning of the cycle.It gradually ramps until it reaches the point of maximum duty cycle.

In one embodiment, the ramp is substantially linear with time. Inanother embodiment, the ramp can also be nonlinear depending on therequirements of the power supply in which the regulator is used. Theintrinsic current limit threshold is basically proportional to thevoltage seen at the input of the current limit comparator. This biasvoltage is the product of the resistor value and the current deliveredto this resistor. One way to increase the intrinsic current limitlinearly as a function of the elapsed time would then be to derive alinearly increasing (with elapsed time) current source and deliver thiscurrent to the resistor. This linearly increasing (with elapsed time)current source can thus be derived from the oscillator.

FIG. 1 shows a schematic of one embodiment of a switched mode powersupply in accordance with the teachings of the present invention. All ofthe circuitry shown in this schematic is used to control the switchingof the power MOSFET 2. The timing of the switching is controlled byoscillator 5. Oscillator 5 generates three signals: Clock 10, DMAX(Maximum duty cycle) 15, and Sawtooth 20. The rising edge of Clocksignal 10 determines the beginning of the switching cycle. As shown inthe illustrated embodiment, when Clock signal 10 is high, output latch90 is set, which results in a control signal output from output latch 90to enable power MOSFET 2 to begin conducting. The maximum conductingtime is determined by DMAX 15 signal being high. When DMAX 15 signalgoes low, latch 90 is reset, thus causing the control signal output fromlatch 90 to disable power MOSFET 2 from conducting.

The intrinsic current limit is, to the first order proportional to thevoltage on node 22. As stated earlier, the goal of the invention is togenerate an intrinsic current limit proportional to the time elapsed inthe switching cycle. The saw tooth waveform 20 can be used to performthis task. As the base voltage of NPN transistor 30 rises, the emittervoltage also rises at the same rate. Thus, the current through resistor25 is linearly increasing with time elapsed during the switching cycle.After mirroring this current through current mirror 40, the linearlyincreasing (with elapsed time) current source 27 is derived. The currentlimit threshold 22 is thus proportional to the product of thecombination of linearly increasing current source 27 and constantcurrent source 50 with the resistor 17. The voltage on node 37 isproportional to the power MOSFET drain voltage because of the voltagedivider network formed by resistors 55 and 60. The drain current isproportional to the drain voltage. As the drain current 7 ramps upduring the switching cycle, the voltage on node 37 risesproportionately. After the voltage on node 37 exceeds the voltage oncurrent limit threshold node 22, comparator 70 disables the power MOSFETby ultimately resetting latch 90.

PWM Comparator 32 modulates the duty cycle based on the feedback signalcoming from the output of the power supply. The higher the feedbackvoltage, the higher the duty cycle will be.

FIG. 2 shows an embodiment of three waveforms: sawtooth 20, duty cyclemax 15, and intrinsic current limit 22. The sawtooth waveform 20 and theduty cycle max waveform 15 are generated by the oscillator 5. The dutycycle max 15 signal determines the maximum duration of a power MOSFETswitching cycle, when it is high. The sawtooth waveform 20 startsincreasing at the low point when the duty cycle max waveform 15 goeshigh. This signals the beginning of the power MOSFET switching cycle.The high point of the sawtooth 20 is reached at the end of the cycle, atthe same time the duty cycle max signal 15 goes low. The intrinsiccurrent limit 22 signal starts at the low point at the beginning of thecycle and then linearly increases with elapsed time throughout thecycle. At a time elapsed of zero, the intrinsic current limit is at K₁As time elapsed increases, the current limit increases by a factor ofK₂*t_(elapsed). As can be seen in FIG. 2 therefore, the intrinsiccurrent limit (I_(LIM-INTRINSIC)) is the sum of K₁ and K₂*t_(elapsed).

FIG. 3 shows one embodiment of a power supply that has an approximatelyconstant voltage and constant current characteristic in accordance withthe teachings of the present invention. An energy transfer element 220is coupled between DC output 200 and HV DC input 255. In one embodiment,energy transfer element is a transformer including an input winding 225and an output winding 215. Regulation circuit 250 is coupled between HVDC input 255 and energy transfer element 220 to regulate DC output 200.In the illustrated embodiment, feedback information responsive to DCoutput 200 is provided to the regulator 250 at its control pin. Thecurrent at the control pin is proportional to the voltage acrossresistor 235, which in turn is related to the output voltage at DCoutput 200.

In operation, the regulator circuit reduces the duty cycle of the powerMOSFET when the voltage across resistor 235 increases above a threshold.In this section, the output is in approximately constant voltage mode.The regulator circuit reduces the current limit of the power MOSFET whenthe voltage across resistor 235 decreases below a threshold. The currentlimit is reduced as a function of the voltage across resistor 235 tokeep the output load current constant. Thus, the load current isproportional to the current limit of the power MOSFET in regulator 250.By keeping the current limit invariant to line voltage, the output loadcurrent would remain constant at all line voltages.

FIG. 4 shows one embodiment of a power supply that has an approximatelyconstant voltage and constant current characteristic in accordance withthe teachings of the present invention. The feedback information isprovided to the regulator 350 at its control pin. The current at thecontrol pin is proportional to the voltage across resistor 335, which inturn is related to the output voltage. The regulator circuit reduces theduty cycle of the power MOSFET when the voltage across resistor 335increases above a threshold. In this section, the output is inapproximately constant voltage mode. The regulator circuit reduces thecurrent limit of the power MOSFET when the voltage across resistor 335decreases below a threshold. The current limit is reduced as a functionof the voltage across resistor 335 to keep the output load currentapproximately constant. Thus, the load current is proportional to thecurrent limit of the power MOSFET in regulator 350. By keeping thecurrent limit substantially constant with line voltage, the output loadcurrent would remain substantially constant at all line voltages.

FIG. 5 is a diagram illustrating the typical relationship between theoutput current and output voltage of one embodiment of a power supply inaccordance with the teachings of the present invention. As can be seenin curve 400, the power supply utilizing the invention exhibits anapproximately constant output current and constant output voltagecharacteristic. That is, as output current increases, the output voltageremains approximately constant until the output current reaches anoutput current threshold. As the output current approaches the outputcurrent threshold, the output voltage decreases as the output currentremains approximately constant over the drop in output voltage until alower output voltage threshold is reached when the output current canreduce further as shown by the range of characteristics. It isappreciated that the constant output voltage and constant output currentcharacteristics of the present invention are suitable for batterycharger applications or the like.

In the foregoing detailed description, the method and apparatus of thepresent invention has been described with reference to specificexemplary embodiments thereof. It will, however, be evident that variousmodifications and changes may be made thereto without departing from thebroader spirit and scope of the present invention. The presentspecification and figures are accordingly to be regarded as illustrativerather than restrictive.

1. A power supply regulator, comprising: a comparator coupled to receivea signal representative of a current through a switch during an on timeof the switch, the comparator further coupled to receive a variablecurrent limit threshold that increases during the on time of the switch;a feedback circuit coupled to receive a feedback signal representativeof an output of a power supply; and a control circuit coupled to theswitch, to an output of the comparator, and to an output of the feedbackcircuit, the control circuit coupled to control a switching of theswitch in response to the output of the comparator and the output of thefeedback circuit to regulate the output of the power supply.
 2. Thepower supply regulator of claim 1 further comprising an oscillatorcoupled to generate a sawtooth waveform, wherein the variable currentlimit threshold is generated in response to the sawtooth waveform. 3.The power supply regulator of claim 2 wherein the feedback circuit isfurther coupled to the oscillator, wherein the feedback circuit isresponsive to the output of the power supply and the sawtooth waveform.4. The power supply regulator of claim 2 wherein the oscillator isfurther coupled to generate a maximum duty cycle signal coupled to bereceived by the control circuit, wherein the control circuit is coupledto control the switching of the switch further in response to themaximum duty cycle signal.
 5. The power supply regulator of claim 2wherein the control circuit further comprises a latch coupled to controlthe switching of the switch, wherein the latch includes a first inputcoupled to be responsive to the output of the comparator.
 6. The powersupply regulator of claim 5 wherein the latch further includes a secondinput coupled to be responsive to a clock signal generated by theoscillator.
 7. The power supply regulator of claim 5 wherein the firstinput of the latch is further coupled to be responsive to a maximum dutycycle signal generated by the oscillator.
 8. The power supply regulatorof claim 5 wherein the feedback circuit includes a feedback comparatorcoupled to receive the feedback signal and to receive the sawtoothwaveform, wherein the first input of the latch is further coupled to beresponsive to the output of the feedback comparator.
 9. The power supplyregulator of claim 1 wherein a duty cycle of a control signal generatedby the control circuit to control the switching of the switch is coupledto be modulated in response to the feedback circuit.
 10. The powersupply regulator of claim 2 further comprising a current mirror coupledto the comparator and to the oscillator, the current mirror coupled togenerate the variable current limit threshold in response to thesawtooth waveform.